Flooring System For Decking

ABSTRACT

The invention provides a flooring system for covering a surface, the system comprising a first portion and a second portion, the first portion being substantially rectangular in cross section and comprising a gripping material, wherein at least one channel is provided in the flooring system and the first portion is located in said channel.

FIELD OF THE INVENTION

The invention relates to a flooring system. Particularly, but notexclusively, the invention relates to a flooring system for decking.

BACKGROUND

Decking is commonly used to extend living areas of houses, being used asan alternative to more traditional stone patios. Generally, the deckingcomprises a series of planks made from, for example, timber, orcomposite materials, or plastics materials. More often, the decking ismade from a selected wood and treated with a preservative to helpmaintain a smooth and polished appearance.

It is a known problem that decking can be hazardous to walk on in wetconditions because the surface of the decking becomes extremelyslippery. Further, wet conditions encourage algal growth on the deckingwhich results in a layer of slime, adding to the slip hazard. One knownway of trying to overcome this problem is by fixing the decking boardssufficiently wide apart to encourage drainage. However, this has thedisadvantage of the boards becoming a trip hazard. Another way ofattempting to overcome the problem is to provide grooves along thelengths of the boards to provide some drainage, or at least to allowwater to move off the surface of the boards.

It is an object of invention to provide a flooring system which attemptsto overcome the aforementioned problems.

SUMMARY OF THE DISCLOSURE

According to an aspect of the present invention there is provided aflooring system for covering a surface, the flooring system comprising afirst portion and a second portion, the first portion beingsubstantially rectangular in cross section and comprising a grippingmaterial, wherein at least one channel is provided in the flooringsystem and the first portion is located in said channel.

Advantageously, the provision of a channel in a flooring system, whereingripping material is provided in the channel, ensures a safer surface onwhich to walk.

Preferably, the at least one channel is provided in the second portion.Preferably, said channel extends parallel to the longitudinal axis ofthe flooring system, preferably parallel to the longitudinal axis of thesecond portion.

Preferably, the channel extends substantially the whole length of theflooring system, preferably, the channel extends substantially the wholelength of the second portion. Preferably, said channel extends coaxialwith the longitudinal axis of the second portion.

Preferably, the at least one channel is rectangular in cross section.Preferably, said channel is substantially between 2 mm and 100 mm indepth, preferably substantially between 2 mm and 100 mm, more preferablysubstantially 6-7 mm in depth.

Preferably, the or each channel has a depth which is less than the depthof the second portion.

Preferably, the at least one channel is substantially between 10 mm and150 mm in width, preferably substantially between 30 mm and 100 mm inwidth.

The width of the channel is preferably at least 8 times, more preferably10 times, more preferably 11 times its depth.

Preferably, the second portion occupies a surface area of at least 50%,preferably at least 70%, more preferably at least 80% of the upper faceof the flooring system.

Preferably, a plurality of channels is provided in the flooring system.Preferably, said plurality of channels extends parallel to each another,preferably, parallel to the flooring system, more preferably, parallelto the longitudinal axis of second portion.

The channels may be flared sidewalls, which are spaced further apart ata top of the channel than at a base of the channel. The flare may beapproximately 2° to 4° from the vertical for each sidewall.

Preferably, two channels are provided in the second portion, each saidchannel extending parallel to the second portion. Preferably, the twochannels are of equal dimension to each other.

Preferably, the first portion extends parallel to the longitudinal axisof the second portion. Preferably, the first portion extendssubstantially the whole length of the second portion.

Preferably, the gripping material extends parallel to the first portion.Preferably, the gripping material extends substantially the whole lengthand preferably substantially the whole width of the first portion.

Preferably, the gripping material is adapted to be repairable. In thismanner, when said material is worn, a person can readily replace thematerial with new material to ensure the non-slip surface is maintained.

Preferably, the gripping material is adapted to lay substantially flushwith a surface of the flooring system, most preferably flush with afirst edge of the second portion.

Preferably, the gripping material is substantially between 2 mm and 100mm in depth, preferably substantially between 2 mm and 10 mm, morepreferably substantially 6-7 mm in depth.

Preferably, the gripping material is substantially between 10 mm and 150mm in width, preferably substantially between 30 mm and 100 mm in width.Preferably, the gripping material substantially fills the channel.

Preferably, the gripping material comprises an elastomer. Morepreferably, the elastomer is a ter polymer. More preferably, theelastomer is a saturated rubber that cannot be cured by sulphurvulcanization. Most preferably, the elastomer is ethylene propylenediene rubber (EPDM), preferably EPDM granules. Preferably, said granulesare in a size range substantially 1 mm to 4 mm, most preferablysubstantially 1 mm to 3 mm. Preferably, the granules are mixed with abinder material. Preferably, the binder material is a moisture curingresin. Preferably, the granules and binder material mix is packed intothe first portion by use of a trowel device.

Advantageously, the granule packing increases the absorption capabilityof the flooring system.

Preferably, the gripping material is bound to the first portion by thebinder material. Preferably, the gripping material is bound to thechannel by the binder material. Preferably, the binder materialcomprises a polyurethane binder.

Preferably, the gripping material comprises thermoplastic vulcanizates(TPV), for example, Santoprene®.

The gripping material may comprise recycled material. Preferably, therecycled material comprises technical scrap. The technical scrap mayinclude reclaimed and recycled EPDM. The scrap may comprise rubbermaterial, for example, car windscreen wiper material, window sealmaterial, and similar materials which show minimal leeching of carbon.

Preferably, the gripping material comprises coloring agents, preferably,synthetic coloring agents, preferably colored EPDM.

Preferably, the second portion comprises a natural material, preferablya wooden material. More preferably, the second layer comprises larch orpine. The second portion may comprise composite materials, or plasticsmaterials.

Preferably, at least one groove is located on the flooring system.Preferably, a plurality of grooves is provided, preferably each saidgroove extending parallel to the longitudinal axis of the flooringsystem.

The flooring system may be manufactured as a retro fit system.

Preferably, the flooring system is adapted to surround a swimming pool.The flooring system may be adapted to match a color of a pool surround.The flooring system may be a terrace, or balcony, or walkway. Theflooring system may be a patio or decking in a garden.

The arrangement of the gripping material in the flooring allows a personto make contact with a gripping surface. In so doing, the person is lesslikely to slip on the flooring.

According to another aspect of the invention there is provided a methodof manufacturing a flooring system comprising first and second portions,the method comprising:

-   -   (a) preparing the second portion with at least one channel        provided therein, and    -   (b) locating the first portion in said channel, the first        portion being substantially rectangular in cross section and        comprising a gripping material.

All of the features described herein may be combined with any of theabove aspects, in any combination.

BRIEF DESCRIPTION OF THE DRAWINGS

An embodiment of the invention will now be described, by way of exampleonly, with reference to the accompanying drawings, wherein:

FIG. 1 shows a schematic plan view of a flooring system according to theinvention;

FIG. 2 shows a schematic side view of a flooring system according to theinvention; and

FIG. 3 shows a schematic plan view of a flooring system according to theinvention.

DETAILED DESCRIPTION

FIGS. 1 to 3 show a flooring system 2 according to the invention. Theflooring system 2 is rectangular in plan view and comprises a firstportion 4 and a second portion 6. When the flooring system 2 is fittedin place, for example, as decking, the second portion 6 forms the lowersurface of the system.

The first portion 4 is located on the second portion 6. The firstportion 4 houses a gripping (or non-slip) material 8, for example, anelastomer. The preferred elastomer is a mix of recycled and/or virginethylene propylene diene rubber (EPDM). The gripping material 8 may besecured into the first portion 4 by suitable adhesives, oralternatively, may be push fitted or slipped into the first portion 4.The use of EPDM and a binder that is spread into the groove when “wet”or before it sets allows the binder that binds the EPDM together also tobind the second portion 6 to the first portion 4. The use of the firstportion 4 described allows flexing and expansion/contraction of a woodensecond portion 6; up to 15 mm of expansion or contraction can be cateredfor. The binder does not stain the wood.

The second portion 6 comprises a substantially rigid material, forexample, a wooden material.

A channel 10 is located in the flooring system 2. The channel 10 issubstantially rectangular in cross section and extends along the lengthof the second portion 6, parallel to the longitudinal axis 12 thereof.The first portion is located in the channel 10. The gripping material 8substantially fills the channel 10 and extends so as to be flush with anedge 12 of the second portion 6. In this manner, the surface of theflooring system 2 remains level, and a tripping hazard is reduced.

The channel 10 may typically be approximately 190 mm wide, 7 mm deep andas long as the second portion. The channel 10 may optionally haveslightly flared sidewalls to aid machining. The sidewalls may flare byapproximately 3°. The profile of the second portion 6 is manufactured inone process in this embodiment. The shoulders and groove are produced atthe same time.

Sidewalls 16 are provided on the second portion 6. The sidewalls 16comprise a shoulder portion 17 which may act 30 as a gully to drainexcess fluid from the flooring system 2 and aid in achieving a non-slipsurface. The sidewalls 16 extend the length of the flooring system 2, ina direction parallel to the longitudinal axis 12 of the second portion6.

Another embodiment of the invention is shown in FIG. 3 wherein two firstportions 104 are provided in the flooring system 100. Said portions 104are arranged to extend parallel to one another and parallel to thelongitudinal axis 110 of the second portion 106.

Grooves 118 are located on each second portion 106. The grooves 118 arecut outs, provided along substantially the whole length of the secondportion 106. The grooves 118 act as gullies to encourage drainage. Thegrooves 118 may also be provided in the embodiment shown in FIG. 1.

It will be understood that a plurality of first portions 4 of the sameor varying widths or lengths may be provided in a flooring system 2 toachieve a safer non-slip surface on which to walk.

The first portions 4 may extend over approximately 80% to 85% of theupper surface area of the flooring system.

During assembly, a number of units of the flooring system 2 are laidadjacent to each other, in a similar manner to planks of timber, andsecured together in the usual manner for decking materials to provide afloor covering. The floor covering may be a decking area, for example,in a garden or surrounding a pool. The flooring system may be providedas a retrofit, for example by preparing a groove in existing decking andinserting the gripping material in the groove.

During use, the gripping material 8 may become worn. Advantageously, thepresent invention provides for said material 8 to be repairable withinthe flooring system 2 and by being replaced with new gripping material8.

The parallel sides of the groove 10/118 facilitate easy placing andreplacing of the gripping material 8 compared to a groove withoverhanging edges.

Advantageously, each individual floor system 2 making up the floorcovering comprises gripping material 8. The arrangement provides anon-slip surface on which a person can walk with a reduced likelihood ofslipping.

The presence of the gripping material provides an aesthetically pleasingdifference to a wooden floor, because the colour and size of thegripping material adds extra options for changing the appearance of thebase second portion 106.

Further advantages of the system described are that the grippingmaterial has sound deadening properties, because of its resilientphysical characteristics. This feature also reduces the pain and injuryof a fall on the surface. The use of a wet pour method gives goodworkability.

The reader's attention is directed to all papers and documents which arefiled concurrently with or previous to this specification in connectionwith this application and which are open to public inspection with thisspecification, and the contents of all such papers and documents areincorporated herein by reference.

All of the features disclosed in this specification (including anyaccompanying claims, abstract and drawings), and/or all of the steps ofany method or process so disclosed, may be combined in any combination,except combinations where at least some of such features and/or stepsare mutually exclusive.

Each feature disclosed in this specification (including any accompanyingclaims, abstract and drawings) may be replaced by alternative featuresserving the same, equivalent or similar purpose, unless expressly statedotherwise. Thus, unless expressly stated otherwise, each featuredisclosed is one example only of a generic series of equivalent orsimilar features.

The invention is not restricted to the details of the foregoingembodiment(s). The invention extends to any novel one, or any novelcombination, of the features disclosed in this specification (includingany accompanying claims, abstract and drawings), or to any novel one, orany novel combination, of the steps of any method or process sodisclosed.

1. A flooring system for covering a surface, the flooring systemcomprising a first portion and a second portion, the first portion beingsubstantially rectangular in cross section and comprising a grippingmaterial, wherein at least one channel is provided in the flooringsystem and the first portion is located in said channel.
 2. The flooringsystem of claim 1, in which the at least one channel is provided in thesecond portion.
 3. The flooring system of claim 1, in which the channelextends substantially the whole length of the flooring system.
 4. Theflooring system of claim 1, in which the at least one channel isrectangular in cross section.
 5. The flooring system of claim 1, inwhich a plurality of channels is provided in the flooring system, saidplurality of channels extending substantially parallel to a longitudinalaxis of second portion.
 6. The flooring system of claim 1, in which twochannels are provided in the second portion.
 7. The flooring system ofclaim 1, in which the gripping material is adapted to lay substantiallyflush with a surface of the flooring system.
 8. The flooring system ofclaim 1, in which the gripping material comprises an elastomer.
 9. Theflooring system of claim 8, in which the elastomer is ethylene propylenediene rubber (EPDM).
 10. The flooring system of claim 9, in which theelastomer includes EPDM granules mixed with a binder material.
 11. Theflooring system of claim 10, in which the gripping material is bound tothe first portion by the binder material.
 12. The flooring system ofclaim 1, in which the first portion and second portion are adapted tosurround a swimming pool.
 13. A method of manufacturing a flooringsystem comprising first and second portions, the method comprising:preparing the second portions with at least one channel providedtherein, and locating the first portion in said channel, the firstportion being substantially rectangular in cross section and comprisinga gripping material.
 14. The method of claim 13, wherein the secondportions are installed in a flooring system without the at least onechannel and the at least one channel is prepared in the second portionsafter installation.
 15. A flooring system for covering a surface, theflooring system comprising a first portion and a second portion, thefirst portion being substantially rectangular in cross section andcomprising a gripping material, the second portion having a surface andat least one channel for receiving the first portion, wherein the atleast one channel extends substantially the whole length of the flooringsystem and the gripping material comprises an elastomer and is adaptedto lay substantially flush with the surface of the second portion,further wherein the gripping material is bound to the first portion bythe binder material.